Vehicle-mounted acdc charging circuit, charging module and working method thereof

Abstract

The application provides a vehicle-mounted ACDC charging circuit, a charging module and a working method thereof. The charging circuit comprises an input module, an output module and a charging management module; the charging management module is connected between the input module and the output module; the input module inputs commercial power and converts the input voltage to provide an effective voltage for the charging management module and a working load; and the output module inputs the voltage to a charging device. The active power factor correction circuit adopts a three-stage interleaved parallel Boost topology structure, takes an average current as a control strategy, and realizes power factor correction through a double closed loop of current and voltage; meanwhile, a phase-shift full-bridge control circuit is adopted, a clamping capacitor and a freewheeling diode are added to the secondary side of the transformer to reset the main current, so that the power switching device of the main circuit works in a zero-voltage and zero-current state; thereby the power transmission efficiency of the wireless charging system is improved, the harmonic pollution is reduced, the power factor of the grid side is improved, and the quality of the output power is ensured.

Description

Technical Field

[0001] This invention relates to the field of vehicle charging, and more particularly to a vehicle-mounted AC / DC charging circuit, a charging module, and a method for operating the same. Background Technology

[0002] An on-board charger is a charger that is fixedly installed on an electric vehicle. It has the ability to safely and automatically fully charge the electric vehicle's power battery. Based on the data provided by the battery management system (BMS), the charger can dynamically adjust the charging current or voltage parameters and perform corresponding actions to complete the charging process.

[0003] Existing charging equipment mainly includes on-board chargers and charging piles, as well as wired and wireless charging technologies. However, charging systems generally include four power conversion stages, but the power conversion stages in existing technologies cannot guarantee stable efficiency, resulting in a decrease in charging efficiency. At the same time, high-power charging equipment can cause harmonic pollution to the power grid, reduce the power supply quality of the power grid, and affect the normal operation of other equipment in the power grid. Summary of the Invention

[0004] Purpose of the invention: To propose an on-board AC / DC charging circuit for vehicles, and further to propose a charging module including the above-mentioned charging circuit and its working method, thereby solving the above-mentioned problems existing in the prior art.

[0005] In a first aspect, an on-board AC / DC charging circuit is proposed, characterized in that it includes an input module, an output module, and a charging management module;

[0006] The charging management module is connected between the input module and the output module; the input module receives AC power and converts the input voltage to provide an effective voltage for the charging management module and the workload; the output module inputs the voltage to the charging device.

[0007] The input module includes an active power factor correction circuit, a phase-shifting full-bridge control circuit, a first transformer, and a second transformer. The input terminal of the active power factor correction circuit receives the mains voltage, and its output terminal is connected to the input terminal of the phase-shifting full-bridge control circuit. The output terminal of the phase-shifting full-bridge control circuit is connected to the input terminals of the first transformer and the second transformer, respectively.

[0008] The charging management module includes: a rectifier, a relay, a battery, a first controller, and an optocoupler;

[0009] The input terminal of the rectifier is connected to the output terminal of the first transformer, and the output terminal is connected to the input terminal of the relay. The output terminal of the relay is connected to the input terminal of the battery, and the control terminal is connected to the input terminal of the first controller. The output terminal of the battery is connected to the input terminal of the first controller, the input terminal of the first controller is connected to the output terminal of the second transformer, and the output terminal is connected to the input terminal of the optocoupler.

[0010] In a further embodiment of the first aspect, the output module includes an interface and a second controller; the input terminal of the second controller is connected to the output terminal of the optocoupler, and the interface is connected to the output terminal of the second controller.

[0011] In a further embodiment of the first aspect, the active power factor correction circuit includes a main circuit and a control circuit; the main circuit is composed of a three-stage interleaved parallel Boost circuit; each stage of the Boost circuit consists of an inductor, a switching transistor, and a freewheeling diode; the control circuit consists of a control chip, a voltage loop compensation circuit, a current loop compensation circuit, and peripheral circuits.

[0012] In a further embodiment of the first aspect, the phase-shifted full-bridge control circuit comprises field-effect transistors S1 to S4, capacitors C1, C3, Co and Cc, inductors Lo and Llk, transformer T, freewheeling diodes D1 to D4, diodes Dc and Dh, and resistor Ro; wherein, the field-effect transistors S1 to S4 form a power switching device, capacitors C1 and C3 are connected in parallel on the leading arm of the power switching device, the input terminal of the power switching device is connected to the input terminal of the transformer T, the inductor Llk is the leakage inductance of the transformer T, the output terminal of the transformer T is connected to the input terminal of an auxiliary circuit composed of capacitor Cc and two diodes Dc and Dh, the output terminal of the auxiliary circuit outputs a voltage, the inductor Lo is the output filter inductor, the capacitor Co is the output filter capacitor, and the resistor Ro is used for output protection.

[0013] Secondly, an on-board ACDC charging module is proposed, which includes a module upper board, a module base, a main control circuit board, multiple external connecting components and multiple segmented connecting components;

[0014] The module's upper plate has multiple first through holes;

[0015] A module base is disposed on one side of the upper plate of the module, and the module base has multiple second through holes;

[0016] The main control circuit board is located between the module base and the module upper plate. The main control circuit board has multiple third through holes and a first slot. The main control circuit board is provided with the vehicle-mounted ACDC charging circuit disclosed in the first aspect.

[0017] Multiple external connecting components are correspondingly connected to the module base, including an external connecting post adapted to the first slot. The side of the external connecting post away from the module base has a slot. Each of the multiple slots is equipped with a segmented connecting component for connecting the module upper plate, the module base, the main control circuit board and the external connecting components.

[0018] The external connecting component also includes a connecting base, a first internal threaded groove, and a first bolt;

[0019] The connecting base is threadedly connected to the side of the external connecting post near the module base;

[0020] The first internal thread groove is formed on the side of the connecting base away from the external connecting post;

[0021] The first bolt is adapted to the first internal thread groove. The first bolt passes through the second through hole and is threadedly connected to the connecting base to fix the connecting base and the module base.

[0022] In a further embodiment of the second aspect, the external connection component further includes a first gasket; the first gasket is disposed between the first bolt and the inner wall of the module base for fastening the module base and the first bolt, wherein the first gasket is made of a non-metallic material to reduce interference with electronic components.

[0023] In a further embodiment of the second aspect, the external connecting component further includes a cross-shaped locking seat and a second locking slot;

[0024] A cross-shaped clamping seat is connected to the side of the connecting base away from the module base, and is used to connect segmented connecting components;

[0025] The second slot is located on the side of the outer connecting post away from the connecting base, and is used to connect the segmented connecting components with the cross-shaped clamping seat.

[0026] In a further embodiment of the second aspect, the segmented connecting component includes a connecting bracket, a connecting top post, a connecting middle post, a second internal threaded groove, and a second bolt;

[0027] The connector is compatible with the slot;

[0028] The connecting top post is adapted to the slot, and a connecting middle post is threadedly connected between the connecting top post and the connecting card seat. The connecting card seat, connecting middle post and connecting top post are respectively provided with second internal thread grooves. In actual use, an appropriate number of connecting middle posts are selected according to the height of the outer connecting post and installed between the connecting card seat and the connecting top post, so that the height of the connecting card seat, connecting middle post and connecting top post or the connecting card seat and connecting top post after installation is adapted to the height of the slot.

[0029] The second bolt is adapted to the second internal thread groove. The second bolt passes through the first through hole and the third through hole and is threadedly connected to the connecting bracket, the connecting top post and the connecting middle post. It is used to fix the module upper plate, the main control circuit board and the segmented connecting components. Different numbers of connecting middle posts are installed in the outer connecting posts of different heights and cooperate with the connecting bracket and the connecting top post. The number of connecting middle posts can be zero.

[0030] In a further embodiment of the second aspect, the segmented connecting component further includes a second gasket; the second gasket is disposed between the second bolt and the module upper plate and the main control circuit board, for fastening the second bolt to the module upper plate and the main control circuit board, wherein the second gasket is made of non-metallic material, which can reduce interference to electronic components.

[0031] In a further embodiment of the second aspect, the segmented connecting component further includes a connecting top plate, a plurality of connecting blocks, and a cross-shaped connecting slot;

[0032] The connecting top plate is connected to the side of the connecting top post away from the connecting middle post. The side of the connecting top plate close to the connecting middle post is connected to a plurality of connecting blocks that are adapted to the second slot, which are used to snap the connecting top post and the outer connecting post. The connecting top plate and the connecting blocks are both made of non-metallic material to reduce interference with electronic components.

[0033] A cross-shaped connecting slot is provided on the side of the connecting bracket away from the connecting central post and is adapted to the cross-shaped clamping seat for engaging the connecting bracket and the connecting base.

[0034] Thirdly, a working method for an on-board ACDC charging circuit is proposed, including the following steps:

[0035] Step 1: Field-effect transistors S1 and S4 are turned on, and energy is output from the primary side to the secondary side, and the clamping capacitor Cc is charged to its maximum value.

[0036] Step 2: Turn off the field-effect transistor S1. The primary current Ip charges capacitor C1 and discharges capacitor C3. Due to the presence of capacitor C1, S1 is a zero-voltage off segment. At this time, the leakage inductance and the output filter inductor Lo are connected in series and jointly provide energy.

[0037] Step 3: Both the primary and secondary voltages decrease. When the secondary voltage drops to the clamping capacitor voltage, the secondary voltage decreases more slowly than the primary voltage due to the clamping capacitor Cc, resulting in a voltage difference that acts on the inductor Llk, causing the primary current to decrease.

[0038] Step 4: C3 discharges to zero, providing the condition for S3 to turn on at zero voltage; the induced voltage on the secondary side acts on the inductor Llk, accelerating the decrease of the primary current Ip until Ip is completely reset.

[0039] Step 5: Clamping capacitor Cc provides load current, and the secondary voltage drops; when clamping capacitor Cc is fully discharged, rectifier diodes D1 to D4 are all conducting freewheeling. During the freewheeling period, since the primary current has been reset, MOSFET S4 is turned off and MOSFET S2 is turned on. Since the primary current of inductor Llk cannot change abruptly, MOSFET S4 is turned off with zero current and MOSFET S2 is turned on with zero current.

[0040] Beneficial Effects: This invention relates to an on-board AC / DC charging circuit, a charging module, and its operating method. The charging circuit comprises an active power factor correction circuit, a phase-shifting full-bridge control circuit, a first transformer, a second transformer, a rectifier, a relay, a battery, a first controller, an optocoupler, an interface, and a second controller. The active power factor correction circuit adopts a three-stage interleaved parallel Boost topology, using average current as the control strategy, and achieves power factor correction through a dual closed-loop of current and voltage. This improves the power transmission efficiency of the wireless charging system, reduces harmonic pollution, improves the power factor on the grid side, and ensures the quality of the output power. Furthermore, this invention optimizes the structure of the charging module. By setting external connecting components and segmented connecting components between the module's upper board, module base, and main control circuit board, it not only improves the connection stability of the module's upper board, module base, and main control circuit board, but also facilitates the replacement of connecting components, reducing wear on connecting components that could affect the stability of the connections between components, and protecting the normal connection and use of the module components. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the AC / DC charging circuit of the present invention.

[0042] Figure 2 This is a schematic diagram of an active power factor correction circuit in one embodiment.

[0043] Figure 3 This is a schematic diagram of a phase-shifted full-bridge control circuit in one embodiment.

[0044] Figure 4 This is a usage state diagram of the charging module in one embodiment of the present invention.

[0045] Figure 5 This is a perspective view of the structure of the module upper board, module base and main control circuit board in one embodiment of the present invention.

[0046] Figure 6 This is an exploded view of the external connecting component and the segmented connecting component in one embodiment of the present invention.

[0047] Figure 7 This is an exploded view of the external connecting component and the segmented connecting component from another perspective in one embodiment of the present invention.

[0048] The reference numerals in the figures are as follows: 1. Module top plate; 101. First through hole; 2. Module base; 201. Second through hole; 3. Main control circuit board; 301. Third through hole; 302. First slot; 4. External connecting component; 401. External connecting post; 402. Slot; 403. Connecting base; 404. First internal thread groove; 405. First bolt; 406. First washer; 407. Cross clamping seat; 408. Second slot; 5. Segmented connecting component; 501. Connecting card. 502. Connecting middle column, 503. Connecting top column, 504. Second bolt, 505. Second washer, 506. Connecting top plate, 507. Connecting clip, 508. Cross connecting slot, 509. Second internal thread slot, A. Active power factor correction circuit, B. Phase-shifting full-bridge control circuit, C. First transformer, D. Second transformer, E. Rectifier, F. Relay, G. Battery, H. First controller, I. Optocoupler, J. Interface, K. Second controller. Detailed Implementation

[0049] In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention can be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described in order to avoid obscuring the invention.

[0050] Example 1:

[0051] The applicant's research found that existing charging equipment mainly includes on-board chargers and charging piles, and wired charging technology and wireless charging. However, charging systems generally include four power conversion stages, but the power conversion stages in existing technologies cannot guarantee stable efficiency, resulting in a decrease in charging efficiency. At the same time, high-power charging equipment will bring harmonic pollution to the power grid, reduce the power supply quality of the power grid, and affect the normal operation of other equipment in the power grid.

[0052] Therefore, this embodiment discloses a main control circuit board for an on-board ACDC charging module, the main control circuit board being composed of an input module, an output module, and a charging management module;

[0053] The charging management module is connected between the input module and the output module. The input module receives AC power and converts the input voltage to provide an effective voltage for the charging management module and the workload. The output module inputs the voltage to the charging device.

[0054] The input module consists of an active power factor correction circuit, a phase-shifting full-bridge control circuit, a first transformer, and a second transformer. The input terminal of the active power factor correction circuit receives the mains voltage, and its output terminal is connected to the input terminal of the phase-shifting full-bridge control circuit. The output terminal of the phase-shifting full-bridge control circuit is connected to the input terminals of the first transformer and the second transformer, respectively.

[0055] The charging management module includes: a rectifier, a relay, a battery, a first controller, and an optocoupler; the input terminal of the rectifier is connected to the output terminal of the first transformer, and the output terminal is connected to the input terminal of the relay; the output terminal of the relay is connected to the input terminal of the battery, and the control terminal is connected to the input terminal of the first controller; the output terminal of the battery is connected to the input terminal of the first controller; the input terminal of the first controller is connected to the output terminal of the second transformer, and the output terminal is connected to the input terminal of the optocoupler.

[0056] The output module includes: an interface and a second controller; the input terminal of the second controller is connected to the output terminal of the optocoupler, and the interface is connected to the output terminal of the second controller.

[0057] Example 2:

[0058] Based on Embodiment 1, the active power factor correction circuit consists of a main circuit and a control circuit; the main circuit is composed of a three-stage interleaved parallel Boost circuit; each stage of the Boost circuit consists of an inductor, a switching transistor, and a freewheeling diode; the control circuit consists of a control chip, a voltage loop compensation circuit, a current loop compensation circuit, and peripheral circuits.

[0059] Specifically, such as Figure 2 As shown, L1, L2, and L3 are boost inductors, IGBT1, IGBT2, and IGBT3 are switching transistors, and FRD1, FRD2, and FRD3 are freewheeling diodes. The first-stage boost circuit consists of L1, IGBT1, and FRD1; the second-stage boost circuit consists of L2, IGBT2, and FRD2; and the third-stage boost circuit consists of L3, IGBT3, and FRD3.

[0060] The output voltage of the three-stage interleaved parallel Boost circuit is sampled using voltage divider resistors RFB1, RFB2, and RFB3, and compared with the DC reference voltage within the FAN9673 control chip. The output signal is then amplified by a voltage error amplifier and output to the multiplier of the FAN9673 control chip. The input voltage is fed into the multiplier after passing through sampling resistors and voltage feedforward compensation. The multiplier's output current serves as the reference current for the inner current loop. The inductor current is compared with this reference current, amplified by a current error amplifier, and then output to a PWM comparator to generate a PWM signal controlling the IGBT's on / off state. This allows the inductor current to follow the waveform of the rectified voltage, reducing current harmonics and improving the power factor.

[0061] Furthermore, the three-stage interleaved parallel Boost circuit has three independent current inner loops, all sharing a single reference current. The current inner loop compensation network consists of resistors RI and capacitors CI1 and CI2.

[0062] The three-stage interleaved parallel Boost APFC circuit has three independent inner current loops, but shares one outer voltage loop. The outer voltage loop compensation network consists of resistor RV and capacitors CV1 and CV2.

[0063] Example 3:

[0064] Based on Embodiment 1 or 2, the phase-shifting full-bridge control circuit consists of field-effect transistors S1 to S4, capacitors C1, C3, Co and Cc, inductors Lo and Llk, transformer T, freewheeling diodes D1 to D4, diodes Dc and Dh, and resistor Ro.

[0065] The field-effect transistors S1 to S4 form a power switching device. Capacitors C1 and C3 are connected in parallel on the leading arm of the power switching device. The input terminal of the power switching device is connected to the input terminal of the transformer T. The inductor Llk is the leakage inductance of the transformer T. The output terminal of the transformer T is connected to the input terminal of an auxiliary circuit consisting of capacitor Cc and two diodes Dc and Dh. The output terminal of the auxiliary circuit outputs a voltage. Inductor Lo is the output filter inductor, capacitor Co is the output filter capacitor, and resistor Ro is used for output protection.

[0066] In the above, such as Figure 3 As shown, S1, S2, S3, and S4 are power switching devices, C1 and C3 are parallel capacitors of the lead-up bridge arm, Llk is the leakage inductance of the transformer, T is the transformer, D1, D2, D3, and D4 are freewheeling diodes, the auxiliary circuit consists of clamping capacitor Cc and two diodes Dc and Dh, Lo is the output filter inductor, and Co is the output filter capacitor.

[0067] First, switches S1 and S4 are turned on, and energy is output from the primary side to the secondary side, charging the clamping capacitor Cc to its maximum value. When S1 is turned off, the primary current Ip charges C1 and discharges C3. Due to the presence of C1, S1 is in a zero-voltage off state. At this time, the leakage inductance and the output filter inductor Lo are connected in series, jointly providing energy. Both the primary and secondary voltages decrease. When the secondary voltage drops to the clamping capacitor voltage, due to the effect of Cc, the secondary voltage decreases more slowly than the primary voltage, resulting in a voltage difference that acts on Llk, causing the primary current to decrease. C3 discharges to zero, providing the condition for zero-voltage turn-on of S3. The induced voltage on the secondary side acts on Llk, accelerating the decrease of the primary current Ip until Ip is fully reset. The switching mode is +1 / 0; the 0 state is in current reset mode. The clamping capacitor Cc provides the load current, and the secondary voltage decreases. When Cc is fully discharged, all rectifier diodes D1 to D4 are conducting and freewheeling. During the freewheeling period, since the primary current has been reset, S4 is turned off and S2 is turned on. Since the primary current of the leakage inductance Llk cannot change abruptly, S4 is turned off with zero current and S2 is turned on with zero current.

[0068] Example 4:

[0069] Further research by the applicant revealed that existing onboard AC / DC charging modules often use connecting posts and screws to connect the module top plate and module base. The connecting posts are mostly made of plastic, and the internal threads of the connecting posts are prone to wear during repeated screwing and unscrewing. This not only affects the tightening of the screws and causes the connection between the module top plate and module base to become loose, but may also affect the fixation of electronic components between the module top plate and module base, posing certain potential risks.

[0070] Therefore, the applicant proposes an on-board ACDC charging module, such as... Figures 1-4 As shown, it includes a module top plate 1, a module base 2, a main control circuit board 3, multiple external connecting components 4, and multiple segmented connecting components 5. The main control circuit board 3 here is the main control circuit board composed of an input module, an output module, and a charging management module mentioned in embodiments one to three above.

[0071] The module upper plate 1 has multiple first through holes 101.

[0072] The module base 2 is located on one side of the module upper plate 1, and multiple second through holes 201 are provided on the module base 2.

[0073] The main control circuit board 3 is located between the module base 2 and the module upper plate 1. The main control circuit board 3 has multiple third through holes 301 and first slots 302.

[0074] Specifically, the specific structure and principle of the module upper plate 1, the first through hole 101, the module base 2, the second through hole 201, the main control circuit board 3, the third through hole 301 and the first card slot 302 can be referred to the vehicle-mounted ACDC charging module in the prior art. The module upper plate 1, the module base 2 and the main control circuit board 3 are also equipped with a predetermined number and type of electronic components, which together constitute the charger module.

[0075] Example 5:

[0076] like Figures 1-4 As shown, multiple external connecting components 4 are connected to the module base 2, including an external connecting post 401 that is adapted to the first slot 302. The side of the external connecting post 401 away from the module base 2 has a slot 402. Each of the multiple slots 402 has a segmented connecting component 5 for connecting the module upper plate 1, the module base 2, the main control circuit board 3 and the external connecting components 4.

[0077] The slot 402 is set through the external connecting post 401. The external connecting post 401 has a variety of height specifications, which can be selected according to the specific use case.

[0078] like Figures 3-4 As shown, the external connecting component 4 also includes a connecting base 403, a first internal thread groove 404, and a first bolt 405.

[0079] The connecting base 403 is threadedly connected to the side of the external connecting post 401 near the module base 2.

[0080] In this application, a third internal thread groove is provided on the inner wall of the slot 402 near the end of the connecting base 403, and a first external thread groove adapted to the third internal thread groove is provided on the outer wall of the connecting base 403 for threaded connection between the connecting base 403 and the outer connecting post 401.

[0081] The first internal thread groove 404 is formed on the side of the connecting base 403 away from the external connecting post 401.

[0082] The first bolt 405 is adapted to the first internal thread groove 404. The first bolt 405 passes through the second through hole 201 and is threadedly connected to the connecting base 403 to fix the connecting base 403 and the module base 2.

[0083] In this application, the first internal thread groove 404 is adapted to the first bolt 405. The first bolt 405 passes through the second through hole 201 and can be threadedly connected to the connecting base 403, thereby fixing multiple connecting bases 403 and multiple external connecting posts 401 at predetermined positions on the module base 2.

[0084] Meanwhile, the first bolt 405, the connecting base 403, and the first internal thread groove 404 facilitate the disassembly and assembly of the external connecting component 4 and the module base 2. In actual use, the external connecting component 4 and the module base 2 are not frequently disassembled and assembled, and the thread wear is small and slow. Therefore, the external connecting column 401, the connecting base 403, the first bolt 405, and the connecting base 403 can be directly threaded together.

[0085] Example 6:

[0086] like Figures 1-4 As shown, the external connecting component 4 also includes a first gasket 406.

[0087] The first gasket 406 is disposed between the first bolt 405 and the inner wall of the module base 2, and is used to fasten the module base 2 and the first bolt 405.

[0088] In this application, the inner diameter of the first gasket 406 is larger than the outer diameter of the second through hole 201. The first gasket 406 also serves to protect the surface of the module base 2 and increase the contact area between the first bolt 405 and the module base 2, thereby improving the fastening performance.

[0089] Meanwhile, the first gasket 406 is made of non-metallic material, which can reduce interference with electronic components.

[0090] In addition, the external connecting component 4 also includes a cross-shaped clamping seat 407 and a second slot 408.

[0091] The cross-shaped clamping seat 407 is connected to the side of the connecting base 403 away from the module base 2, and is used to connect the segmented connecting component 5.

[0092] The second slot 408 is located on the side of the outer connecting post 401 away from the connecting base 403, and is used to connect the segmented connecting component 5 with the cross clamping seat 407.

[0093] like Figures 1-4 As shown, the segmented connecting component 5 includes a connecting bracket 501, a connecting top post 503, a connecting middle post 502, a second internal thread groove 509, and a second bolt 504.

[0094] The connecting card holder 501 is compatible with the slot 402.

[0095] The connecting top post 503 is adapted to the slot 402. The connecting top post 503 and the connecting card seat 501 are threadedly connected by a connecting middle post 502. The connecting card seat 501, the connecting middle post 502 and the connecting top post 503 are respectively provided with second internal thread grooves 509.

[0096] In this application, the connecting card holder 501 is inserted at the bottom of the outer connecting post 401 near the connecting base 403, the connecting top post 503 is inserted at the top of the outer connecting post 401 away from the connecting base 403, and several connecting middle posts 502 are inserted in the middle of the outer connecting post 401 and are correspondingly connected between the connecting card holder 501 and the connecting top post 503.

[0097] Among them, the connecting card holder 501, the connecting middle column 502 and the connecting top column 503 are respectively provided with matching external threads and internal threads on their close sides, for the sequential connection of the connecting card holder 501, several connecting middle columns 502 and connecting top columns 503.

[0098] In actual use, select an appropriate number of connecting middle posts 502 based on the height of the outer connecting post 401 and install them between the connecting card holder 501 and the connecting top post 503, so that the height of the connecting card holder 501, connecting middle post 502, connecting top post 503 or the connecting card holder 501 and connecting top post 503 after installation is compatible with the height of the slot 402.

[0099] In addition, the connecting bracket 501, connecting middle post 502 and connecting top post 503 are all made of metal, that is, the second internal thread groove 509 is a metal internal thread, which is more wear-resistant and more durable than plastic internal threads.

[0100] Meanwhile, the connecting bracket 501, connecting middle post 502, and connecting top post 503 are inserted into the outer connecting post 401. If one or more of the second internal thread grooves 509 in the connecting bracket 501, connecting middle post 502, and connecting top post 503 are worn, it is convenient for the user to replace one or more of the connecting bracket 501, connecting middle post 502, and connecting top post 503 without having to disassemble and replace the outer connecting post 401. This makes disassembly and replacement convenient and also reduces material waste.

[0101] The second bolt 504 is adapted to the second internal thread groove 509. The second bolt 504 passes through the first through hole 101 and the third through hole 301 and is threadedly connected to the connecting bracket 501, the connecting top post 503 and the connecting middle post 502 to fix the module upper plate 1, the main control circuit board 3 and the segmented connecting component 5.

[0102] In this application, different numbers of connecting middle columns 502 are installed in the outer connecting columns 401 of different heights, and cooperate with the connecting bracket 501 and the connecting top column 503. The number of connecting middle columns 502 can be zero, and the connecting bracket 501 and the connecting top column 503 can be directly threaded together.

[0103] In use, the second bolt 504 passes through the first through hole 101 and the third through hole 301 respectively and is threadedly connected to the segmented connecting parts 5 in the external connecting post 401 between the module upper plate 1 and the module base 2, as well as the main control circuit board 3 and the module base 2. Thus, the module upper plate 1 and the module base 2, as well as the module base 2 and the main control circuit board 3, can be fixed respectively using the external connecting posts 401 of different heights.

[0104] Example 7:

[0105] like Figures 3-4 As shown, the segmented connecting component 5 also includes a second gasket 505.

[0106] The second gasket 505 is disposed between the second bolt 504 and the module upper plate 1 and the main control circuit board 3, and is used to fasten the second bolt 504 to the module upper plate 1 and the main control circuit board 3.

[0107] In this application, the inner diameter of the second gasket 505 is larger than the outer diameter of the first through hole 101 and the third through hole 301. The second gasket 505 also serves to protect the surface of the module upper plate 1 and increase the contact area between the second bolt 504 and the module upper plate 1, thereby improving the fastening performance.

[0108] In addition, the second gasket 505 is made of non-metallic material, which can reduce interference to electronic components.

[0109] like Figures 1-4 As shown, the segmented connecting component 5 also includes a connecting top plate 506, multiple connecting blocks 507, and a cross-shaped connecting slot 508.

[0110] The connecting top plate 506 is connected to the side of the connecting top post 503 away from the connecting middle post 502. The side of the connecting top plate 506 near the connecting middle post 502 is connected to a plurality of connecting blocks 507 adapted to the second slot 408, which are used to snap the connecting top post 503 and the outer connecting post 401.

[0111] In this application, the connecting top post 503 can be snapped onto the outer connecting post 401 using the connecting top plate 506, multiple connecting blocks 507 and multiple second slots 408, thereby further securing the segmented connecting component 5 and the outer connecting component 4.

[0112] In addition, the connecting top plate 506 and the connecting block 507 are both made of non-metallic materials to reduce interference with electronic components.

[0113] The cross-shaped connector slot 508 is located on the side of the connector base 501 away from the connector center post 502 and is adapted to the cross-shaped clamping seat 407 for engaging the connector base 501 and the connector base 403.

[0114] In this application, the connecting bracket 501 can be engaged with the connecting base 403 through the cross connecting slot 508 and the cross clamping seat 407. It can also work with the connecting top plate 506, the connecting block 507, and the second slot 408 to further clamp the external connecting component 4 and the segmented connecting component 5, thereby improving the stability of the external connecting component 4 and the segmented connecting component 5 after installation.

[0115] Working principle: In use, firstly, the first internal thread grooves 404 of the multiple connecting bases 403 are aligned with the second through holes 201 on the module base 2. Then, the connecting bases 403 are fixed to the module base 2 using the first bolts 405 and the first washers 406. Next, the outer connecting posts 401 are screwed onto the connecting bases 403. After that, the main control circuit board 3 and the module upper plate 1 are respectively abutted against the outer connecting posts 401 at different heights. The third through holes 301 and the second through holes 201 on the main control circuit board 3 and the module upper plate 1 are aligned with the slots 402, and the first slot 302 is locked with the corresponding outer connecting post 401.

[0116] Then, based on the height of the external connecting post 401, select the connecting bracket 501, connecting top post 503 and an appropriate number of connecting middle posts 502, tighten them and then insert them into the slot 402. Then, use the second bolt 504 and the second washer 505 to fix the module upper plate 1, module base 2, main control circuit board 3, external connecting component 4 and segmented connecting component 5. When disassembling, simply reverse the above steps. In addition, it should be noted that this is one of the disassembly and assembly methods in this application. When using it, the disassembly and assembly sequence can be selected according to the actual situation.

[0117] As described above, although the invention has been shown and described with reference to specific preferred embodiments, it should not be construed as limiting the invention itself. Various changes in form and detail may be made without departing from the spirit and scope of the invention as defined in the appended claims.

Claims

1. A vehicle-mounted AC / DC charging circuit, characterized in that, It includes an input module, an output module, and a charging management module; The charging management module is connected between the input module and the output module; the input module receives AC power and converts the input voltage to provide an effective voltage for the charging management module and the workload; the output module inputs the voltage to the charging device. The input module includes an active power factor correction circuit, a phase-shifted full-bridge control circuit, a first transformer, and a second transformer. The input terminal of the active power factor correction circuit receives the mains voltage, and its output terminal is connected to the input terminal of the phase-shifted full-bridge control circuit. The output terminal of the phase-shifted full-bridge control circuit is connected to the input terminals of the first transformer and the second transformer, respectively. The active power factor correction circuit includes a main circuit and a control circuit. The main circuit is composed of three-stage interleaved parallel Boost circuits; each stage of the Boost circuit consists of an inductor, a switching transistor, and a freewheeling diode; the control circuit consists of a control chip, a voltage loop compensation circuit, a current loop compensation circuit, and peripheral circuits. The phase-shifting full-bridge control circuit consists of field-effect transistors S1 to S4, capacitors C1, C3, Co and Cc, inductors Lo and Llk, transformer T, freewheeling diodes D1 to D4, diodes Dc and Dh, and resistor Ro. In this circuit, the field-effect transistors S1 to S4 form a power switching device. Capacitors C1 and C3 are connected in parallel on the leading arm of the power switching device. The input terminal of the power switching device is connected to the input terminal of the transformer T. The inductor Llk is the leakage inductance of the transformer T. The output terminal of the transformer T is connected to the input terminal of an auxiliary circuit consisting of capacitor Cc and two diodes Dc and Dh. The output terminal of the auxiliary circuit outputs a voltage. The inductor Lo is the output filter inductor, the capacitor Co is the output filter capacitor, and the resistor Ro is used for output protection. The charging management module includes: a rectifier, a relay, a battery, a first controller, and an optocoupler; The input terminal of the rectifier is connected to the output terminal of the first transformer, and the output terminal is connected to the input terminal of the relay. The output terminal of the relay is connected to the input terminal of the battery, and the control terminal is connected to the input terminal of the first controller. The output terminal of the battery is connected to the input terminal of the first controller, the input terminal of the first controller is connected to the output terminal of the second transformer, and the output terminal is connected to the input terminal of the optocoupler.

2. The charging circuit according to claim 1, characterized in that, The output module includes an interface and a second controller; The input terminal of the second controller is connected to the output terminal of the optocoupler, and the interface is connected to the output terminal of the second controller.

3. A vehicle-mounted AC / DC charging module, characterized in that, include: The module upper plate has multiple first through holes; A module base is disposed on one side of the upper plate of the module, and the module base has multiple second through holes; The main control circuit board is disposed between the module base and the module upper plate, and the main control circuit board has multiple third through holes and a first slot. Multiple external connecting components are connected to the module base, including an external connecting post adapted to the first slot. The side of the external connecting post away from the module base has a slot. Each of the multiple slots is equipped with a segmented connecting component for connecting the module upper plate, the module base, the main control circuit board and the external connecting components. The main control circuit board is equipped with the vehicle-mounted ACDC charging circuit as described in claim 1 or 2.

4. The charging module according to claim 3, characterized in that, The external connection component also includes: The connecting base is threadedly connected to the side of the external connecting post near the module base; The first internal thread groove is formed on the side of the connecting base away from the external connecting post; The first bolt, which is adapted to the first internal thread groove, is used to fix the connection base and the module base. The first gasket is disposed between the first bolt and the inner wall of the module base for fastening the module base and the first bolt. A cross-shaped clamping seat is connected to the side of the connecting base away from the module base and is used to connect segmented connecting components; The second slot is located on the side of the outer connecting post away from the connecting base, and is used to connect the segmented connecting components with the cross-shaped clamping seat.

5. The charging module according to claim 3, characterized in that, The segmented connecting component includes: A connector is provided to fit the slot. A connecting top post is adapted to the slot, and a connecting middle post is threadedly connected between the connecting top post and the connecting card seat. The connecting card seat, the connecting middle post and the connecting top post are respectively provided with second internal thread grooves. The second bolt, which is adapted to the second internal thread groove, is used to fix the module upper plate, the main control circuit board and the segmented connecting components. The second gasket is disposed between the second bolt and the module upper plate and the main control circuit board, and is used to fasten the second bolt to the module upper plate and the main control circuit board.

6. The charging module according to claim 5, characterized in that, The segmented connecting component also includes: A connecting top plate is connected to the side of the connecting top column away from the connecting middle column. The side of the connecting top plate close to the connecting middle column is connected to a plurality of connecting blocks that are adapted to the second slot, for engaging the connecting top column and the outer connecting column. A cross-shaped connecting slot is provided on the side of the connecting bracket away from the connecting central post and is adapted to the cross-shaped clamping seat for engaging the connecting bracket and the connecting base.

7. A method for operating an on-board AC / DC charging circuit according to claim 1 or 2, characterized in that, Includes the following steps: Step 1: Field-effect transistors S1 and S4 are turned on, and energy is output from the primary side to the secondary side, and the clamping capacitor Cc is charged to its maximum value. Step 2: Turn off the field-effect transistor S1. The primary current Ip charges capacitor C1 and discharges capacitor C3. Due to the presence of capacitor C1, S1 is turned off with zero voltage. At this time, the leakage inductance and the output filter inductor Lo are connected in series and provide energy together. Step 3: Both the primary and secondary voltages decrease. When the secondary voltage drops to the clamping capacitor voltage, the secondary voltage decreases more slowly than the primary voltage due to the clamping capacitor Cc, resulting in a voltage difference that acts on the inductor Llk, causing the primary current to decrease. Step 4: C3 discharges to zero, providing the condition for S3 to turn on at zero voltage; the induced voltage on the secondary side acts on the inductor Llk, accelerating the decrease of the primary current Ip until Ip is completely reset; Step 5: the clamping capacitor Cc provides the load current, and the secondary voltage drops; the clamping capacitor Cc discharges completely, and all rectifier diodes D1 to D4 conduct freewheeling. During the freewheeling period, since the primary current has been reset, the field-effect transistor S4 is turned off and the field-effect transistor S2 is turned on. Since the primary current of the inductor Llk cannot change abruptly, the field-effect transistor S4 is turned off at zero current and the field-effect transistor S2 is turned on at zero current.

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